Modular dye meter and method of preparing compounds

ABSTRACT

A method of preparing compounds comprising a plurality of components, the method comprising providing a modular dye meter, introducing component into one or more than one modular batching member of the modular dye meter, where the compound to be prepared comprises the one or more than one component, activating the internal rotor of one or more than one of the batching and delivering devices, thereby causing the internal rotors to rotate in the first direction, where rotation of the internal rotor moves component through the progressive recesses of the batching and delivering device through the corresponding delivery duct and through the dispenser, and thereby into a vessel for containing the compound, causing the rotation of the internal rotor in the first direction to cease, causing the internal rotor to rotate in a second direction, where the second direction is opposite to the first direction, thereby moving component back through the delivery duct into the corresponding batching and delivering device, and causing the rotation of the internal rotor in the second direction to cease.

CROSS-REFERENCE TO RELATED APPLICATION SECTION

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 11/908,940, titled “Modular Dye Meter,” filed Sep.17, 2007, which is a 371 of International Patent Application No.PCT/IT2005/000194, titled “Modular Dye Meter,” filed Apr. 7, 2005, thecontents of which are incorporated in this disclosure by reference intheir entirety.

BACKGROUND

Modular dye meters are used to produce compounds comprising a pluralityof components, such as colored compounds including enamels and paints.Modular dye meters usually comprise a plurality of tanks for storingindividual components and corresponding batching and delivering deviceswhich take specific amounts of each component from the correspondingtank and combine the components depending on desired composition of thecompound. In general, there are two types of dye meters: first, dyemeters with tanks in a fixed position connected through delivery ductsto a delivering head placed above a vessel for receiving the componentsof the compound, where delivery of individual components can occursimultaneously; and second, dye meters where the tanks are placed onplatforms which rotate to place the individual tanks, or individualsub-groups of tanks, in turn, on the vessel to deliver the components ofthe compound. Additionally, some modular dye meters batch componentsbased on weight of the component, and some modular dye meters batchcomponents based on volume of the component. Modular dye meters withweight-based batching are typically more accurate but relatively slowercompared with modular dye meters with volume-based batching.

All known dye meters have several disadvantages. First, they are complexleading to reliability problems over time. In particular, since alltanks share the same dye batching and delivering devices, themalfunction of one tank or even routine maintenance can stop productionof the compound for a considerable time while spare parts andspecialized assistance is obtained. Second, modular dye meters arerelatively costly, particularly for small scale manufacturing. Third,modular dye meters are difficult to reconfigure to change thecomposition of the compound being produced. Fourth, modular dye meterssuffer from dripping problems at the end of the delivery ducts, and insuch drops both waste components and components can solidify within thedelivery ducts causing clogs.

Therefore, there is a need for a modular dye meter and a method ofpreparing compounds that are not associated with these disadvantages.

SUMMARY

According to one embodiment of the present invention, there is provideda method of preparing compounds comprising a plurality of components,the method comprising, a) providing a modular dye meter, where themodular dye meter comprises i) one or more than one modular batchingmember, where each modular batching member comprises a container forstoring one component of the compound and comprises a batching anddelivering device for moving the component stored in the container; ii)a dispenser; and iii) a delivery duct corresponding to each batching anddelivering device, and connecting each batching and delivering device tothe dispenser; where each batching and delivering device comprises apump comprising an inlet end connected to the container, and comprisesan outlet end connected to the delivery duct; where each pump comprisesan external stator housing and an internal rotor within the externalstator, where the internal rotor has an axis of rotation, and where theinternal rotor is capable of rotating in a first direction around theaxis of rotation, and is capable of rotating in a second direction thatis around the axis of rotation and where the first direction is oppositeof the second direction; where each external stator housing comprisesprogressive recesses and each internal rotor comprises progressiverecesses; where rotation of the internal rotor relative to the externalstator housing moves component inside the pump through the progressiverecesses and toward the delivery duct when the internal rotor rotates inthe first direction, or away from the delivery duct when the internalrotor rotates in the second direction. Next, the method comprisesintroducing component into one or more than one modular batching memberof the modular dye meter, where the compound to be prepared comprisesthe one or more than one component. Then, the method comprisesactivating the internal rotor of one or more than one of the batchingand delivering devices, thereby causing the internal rotors to rotate inthe first direction, where rotation of the internal rotor movescomponent through the progressive recesses of the batching anddelivering device through the corresponding delivery duct and throughthe dispenser, and thereby into a vessel for containing the compound.Next, the method comprises causing the rotation of the internal rotor inthe first direction to cease. Then, the method comprises causing theinternal rotor to rotate in a second direction, where the seconddirection is opposite to the first direction, thereby moving componentback through the delivery duct into the corresponding batching anddelivering device. Next, the method comprises causing the rotation ofthe internal rotor in the second direction to cease.

In one embodiment, the first direction is clockwise around the axis ofthe internal rotor. In another embodiment, the first direction iscounter-clockwise around the axis of the internal rotor. In oneembodiment, the second direction is clockwise around the axis of theinternal rotor. In another embodiment, the second direction iscounter-clockwise around the axis of the internal rotor.

FIGURES

These and other features, aspects and advantages of the presentinvention will become better understood with regard to the followingdescription, appended claims, and accompanying figures where:

FIG. 1 is a lateral perspective view of one embodiment of a modular dyemeter according to the present invention comprising a plurality ofmodular batching members according to the present invention;

FIG. 2 is a lateral perspective view of one embodiment of a modularbatching member of the modular dye meter shown in FIG. 1;

FIG. 3 is a schematic, cross-sectional lateral perspective view of themodular batching member shown in FIG. 2;

FIG. 4 is a lateral perspective view of a dye metering machine accordingto the present invention comprising the modular dye meter shown in FIG.1; and

FIG. 5 is a lateral perspective cutaway view of the dye metering machineshown in FIG. 4.

DESCRIPTION

According to one embodiment of the present invention, there is provideda modular batching member for use in a modular dye meter. According toanother embodiment of the present invention, there is provided a modulardye meter comprising one or more than one modular batching memberaccording to the present invention. According to another embodiment ofthe present invention, there is provided a dye metering machinecomprising a modular dye meter according to the present invention.According to another embodiment of the present invention, there isprovided a method of preparing compounds. In one embodiment, the methodcomprises providing a modular dye meter according to the presentinvention. The modular dye meter of the present invention can be easily,economically and quickly configured to different production needs withrespect to volumes of components, the number of components or the typeof components that comprise compound. Further, the modular dye meter ofthe present invention is a more accurate and reliable volumetricbatching system than known systems. Additionally, the modular dye meterof the present invention obviates the problem with dripping from thedelivery ducts associated with known systems. The devices and methodwill now be disclosed in detail.

All dimensions specified in this disclosure are by way of example onlyand are not intended to be limiting. Further, the proportions shown inthese Figures are not necessarily to scale. As will be understood bythose with skill in the art with reference to this disclosure, theactual dimensions of any device or part of a device disclosed in thisdisclosure will be determined by its intended use.

The devices of the present invention and their component parts compriseany suitable material for the intended purpose of the device, as will beunderstood by those with skill in the art with reference to thisdisclosure.

The devices of the present invention and their component parts can beconstructed according to standard techniques, as will be understood bythose with skill in the art with reference to this disclosure.

As used in this disclosure, except where the context requires otherwise,the method steps disclosed are not intended to be limiting nor are theyintended to indicate that each step is essential to the method or thateach step must occur in the order disclosed.

According to one embodiment, there is provided a modular dye meter forpreparing a compound from one or more than one component, and inparticular from a plurality of components, such as for example enamelsand paints or other colored compounds. The modular dye meter comprisesone or more than one modular batching member according to the presentinvention, where each modular batching member stores one component thatthe compound comprises. Referring now to FIG. 1, FIG. 2 and FIG. 3,there are shown, respectively, a lateral perspective view of oneembodiment of a modular dye meter according to the present inventioncomprising a plurality of modular batching members according to thepresent invention (FIG. 1); a lateral perspective view of one embodimentof a modular batching member of the modular dye meter shown in FIG. 1(FIG. 2); and a schematic, cross-sectional lateral perspective view ofthe modular batching member shown in FIG. 3. As can be seen, in oneembodiment, the modular dye meter 1 comprises a supporting structure 3and a plurality of seats 5 connected to the supporting structure 3. Themodular dye meter 1 further comprises one or more than one modularbatching member 7, where each modular batching member 7 is connected toone of the plurality of seats 5, such as for example by a mechanicalconnector. The modular dye meter 1 further comprises a dispenser 9, suchas for example a delivering head comprising a plurality of deliveringnozzles. The modular dye meter 1 further comprises one or more than onedelivery duct 11, where each delivery duct connects one modular batchingmember 7 to the dispenser 9, thereby allowing fluid to flow from themodular batching member 7 to the dispenser 9. The dispenser 9 deliversthe individual components from the modular batching members 7 to avessel to produce the compound. In a preferred embodiment, each deliveryduct 11 can be quickly and easily disconnected from the modular batchingmember 7 to allow removal of the modular batching member 7 from thecorresponding seat 5.

As can be seen in FIG. 1 and FIG. 5, in a preferred embodiment, theplurality of seats 5 (and corresponding modular batching members 7 whenconnected) and the corresponding delivery ducts 11 are arranged radiallyaround the dispenser 9; however, the plurality of seats 5 (andcorresponding modular batching members 7 when connected) and thecorresponding delivery ducts 11 can be arranged linearly or in anotherconfiguration, as will be understood by those with skill in the art withreference to this disclosure.

Referring now particularly to FIG. 2 and FIG. 3, each modular batchingmember 7 according to the present invention comprises a container 71,and further comprises a batching and delivering device 75 for batchingand delivering the component contained within the container 71 of themodular batching member 7. In one embodiment, as shown in the Figures,the container 71 is a cylinder; however, the container 71 can be anysuitable shape for the intended purpose, as will be understood by thosewith skill in the art with reference to this disclosure. The modularbatching member 7 further comprises one or more than one blade 72 withinand co-axial with each container 71. Each modular batching member 7further comprises an actuating motor 73 for rotating the one or morethan one blade 72 within the container 71, where rotating the componentin the container 71 keeps the component in suspension. In oneembodiment, the actuating motor 73 is housed in an upper cover 74 of thecontainer 71. As will be understood by those with skill in the art withreference to this disclosure, additional component can be easily addedto the container 71 by removing the upper cover 74 thereby accessing theinterior of the container 71.

In a preferred embodiment, as can be seen in FIG. 1, each of theplurality of seats 5 is connected to a modular batching member 7. Inanother embodiment, at least one of the plurality of seats 5 is notconnected to a modular batching member 7. In another one embodiment,only one seat 5 of the plurality of seats 5 is connected to a modularbatching member 7.

The modular dye meter 1 further comprises managing means for controllingthe batching and delivering device 75. In one embodiment, the modulardye meter 1 further comprises a first electric connection connectingeach one of the plurality of seats 5 to the corresponding modularbatching member 7. The first electric connections supply current from acurrent source to a batching and delivering device 75 of thecorresponding modular batching member 7 according to instructions fromthe managing means to provide the correct amount of component to thedispenser 9. The managing means can be any suitable structure or device,as will be understood by those with skill in the art with reference tothis disclosure, suitable for managing and driving dye meters, suitablymodified to manage the individual modular batching members 7 toguarantee the correct batching of components to produce the compound. Inone embodiment, the managing means is a personal computer. In oneembodiment, the managing means controls the modular batching members 7through the first electric connections. In another embodiment, themanaging means controls the modular batching members 7 by wirelessmeans.

The batching and delivering device 75 delivers specific amounts of thecomponent contained in the container 71 to the dispenser 9 through thedelivery duct 11. In one embodiment, the batching and delivering device75 comprises a second fluid connector connected to the delivery duct 11.The modular dye meter 1 further comprises a second electric connector 77operatively connected to the first electric connector, preferablythrough a quick-connection electric connector or pin 77 without usingtools, to be electrically supplied and controlled by the managing meansfor delivering specific amounts of the component contained in thecontainer 71 to the dispenser 9 through the delivery duct 11.

In a preferred embodiment, as shown particularly in FIG. 3, the batchingand delivering device 75 comprises one or more than one pump 75comprising an inlet end connected to the container 71, and an outlet endconnected to the delivery duct 11. The pump 75 further comprises anexternal stator housing 751 and an internal rotor 753 within theexternal stator, where the internal rotor 753 is rotatingly driven by acontrolling motor 76 equipped with the second electric connector 77. Thepump further comprises progressive recesses in the housing 751. Theinternal rotor 753 is shaped as a worm screw comprising progressiverecesses whose relative rotation with respect to the progressiverecesses in the stator housing 751 moves component inside the pumptoward the delivery duct 11 (and therefore toward the dispenser 9) oraway from the delivery duct 11 (and therefore toward the container 71)depending on the rotational direction of the internal rotor 753. Thespecific amount of component moved depends on the amount of rotation ofthe internal rotor 753. In a preferred embodiment, the outlet end of thepump 75 comprises a quick connector 78 connecting the pump 75 to thedelivery duct 11. As will be understood by those with skill in the artwith reference to this disclosure, the batching and delivering device 75can comprise any other suitable structure including any othercombination of traditional pumping means and valves, both for avolumetric batching and for a weight batching.

The advantages of using a pump 75 with progressive recesses arenumerous. First, when the internal rotor 753 is stopped with respect tothe external stator 751, the pump 75 with progressive recesses producesa perfect seal. Second, the pump 75 is very reliable because the onlymoving part needed to move component is the internal rotor 753 and wearfrom friction due to the relative movement between internal rotor 753and external stator 751 is negligible. Third, contrary to pumps whichutilize a piston where the pumping is cyclic due to the piston stroke,the pump 75 with progressive recesses allows a continuous movement ofthe component from the container 71 to the dispenser 9. Fourth, the pump75 with progressive recesses allows an extremely accurate volumetricdelivery of a component that is proportional to the rotation of theinternal rotor 753 because the rotation of the internal rotor iscontrolled down to the order of fractions of degree by the managingmeans that control the controlling motor 76. Therefore, using the pump75 with progressive recesses obviates the need to calibrate the modulardye meter 1 during installation reducing tooling times and costs.

As will be understood by those with skill in the art with reference tothis disclosure, a modular batching member 7 can be installed in themodular dye meter 1 by inserting the modular batching member 7 in one ofthe seats 5. In one embodiment, the modular batching member 7 is fixedin the corresponding seat 5 with a mechanical connector. Then, thedelivery duct 11 is connected to the modular batching member 7, and thefirst electric connector is connected to the modular batching member 7.Each modular batching member 7 is uninstalled from the modular dye meter1 as needed to replace, maintain or refill the modular batching member 7by reversing the process.

According to another embodiment of the present invention, there isprovided a dye metering machine comprising a modular dye meter accordingto the present invention. Referring now to FIG. 4 and FIG. 5, there areshown, respectively, a lateral perspective view of a dye meteringmachine according to the present invention comprising the modular dyemeter shown in FIG. 1 (FIG. 4); and a lateral perspective cutaway viewof the dye metering machine shown in FIG. 4 (FIG. 5). As can be seen,the dye metering machine 21 comprises a containing structure 12 housinga modular dye meter 1 according to the present invention. The dyemetering machine 21 further comprises a plate 13 that supports andpositions a vessel 15 for receiving the compound from the dispenser 9.In one embodiment, the plate 13 is adjustable relative to the dispenser9, such as for example through a screw-nut screw system or a bypneumatic piston driven by a pedal 17 as shown in FIG. 4, to optimallydetermine the position of the vessel 15 with respect to the dispenser 9.In a preferred embodiment, the containing structure 12 comprises coatingpanels 19 to protect the modular dye meter 1 from external agents. In apreferred embodiment, at least part of the coating panels 19 areconnected to the remainder of the containing structure 12 in a mannersuch that the coating panels 19 can be easily removed without the use oftools, to facilitate access to the modular dye meter 1 for maintenancepurposes or to remove, recharge, add or replace one or more than one ofthe modular batching members 7. Additionally, the containing structure12 comprises means for electrically supplying the modular dye meter 1.

As will be understood by those with skill in the art with reference tothis disclosure, the modular dye meter 1 according to the presentinvention has a series of advantages with respect to known modular dyemeters. These advantages that are related both to practicality of useand to optimization of costs and resources. First, the modular dye meter1 of the present invention can be configured for use with only theminimum number of modular batching members 7 containing the types ofcomponents that are necessary for producing the compound. Second, tomodify the composition of the compound being produced, the configurationof modular batching members 7 in the modular dye meter 1 can be quickly,simply and economically changed by replacing one or more than one of themodular batching members 7, or adding additional modular batchingmembers 7 containing the components for new composition. Third, in caseof the malfunction of one or more of the modular batching members 7, themalfunctioning modular batching member 7 can be quickly and simplyreplaced, even without the use of tools and generally without the needfor service from the manufacturer, or if a spare modular batching member7 is not readily available, production of compounds that do not requirethe component contained in the malfunctioning modular batching member 7can continue avoiding complete cessation of production.

According to another embodiment of the present invention, there isprovided a method of preparing compounds comprising a plurality ofcomponents. In one embodiment, the method comprises providing a modulardye meter according to the present invention, or providing a dyemetering machine comprising a modular dye meter according to the presentinvention. The method further comprises introducing one component intoone or more than one modular batching member of the modular dye meter,where the compound to be prepared comprises the components introduced.Next, the managing means activates the internal rotor of the batchingand delivering devices corresponding to each of the one or more than onemodular batching member causing the internal rotor to rotate in a firstdirection, where rotation of the internal rotor in the first directionmoves component from the corresponding modular batching member throughthe progressive recesses of the batching and delivering device throughthe delivery duct through the dispenser, and thereby into a vessel forcontaining the compound. In one embodiment, the first direction isclockwise around the axis of the internal rotor. In another embodiment,the first direction is counter-clockwise around the axis of the internalrotor. Then, the managing means causes the rotation of the internalrotor in the first direction to cease and causes the internal rotor torotate in a second direction, where the second direction is opposite tothe first direction, thereby moving component from the dispenser backthrough the delivery duct preventing drips of component from exiting thedispenser. Next, the managing means causes the rotation of the internalrotor in the second direction to cease. Movement of the internal statorin the second direction advantageously obviates component waste, andprevents solidifying of excess component within the delivery ducts. Inone embodiment, the second direction is clockwise around the axis of theinternal rotor. In another embodiment, the second direction iscounter-clockwise around the axis of the internal rotor.

Although the present invention has been discussed in considerable detailwith reference to certain preferred embodiments, other embodiments arepossible. Therefore, the scope of the appended claims should not belimited to the description of preferred embodiments contained in thisdisclosure.

1. A method of preparing compounds comprising a plurality of components,the method comprising: a) providing a modular dye meter comprising: i)one or more than one modular batching member, where each modularbatching member comprises a container for storing one component of thecompound and comprises a batching and delivering device for moving thecomponent stored in the container; ii) a dispenser; and iii) a deliveryduct corresponding to each batching and delivering device, andconnecting each batching and delivering device to the dispenser; whereeach batching and delivering device comprises a pump comprising an inletend connected to the container, and comprises an outlet end connected tothe delivery duct; where each pump comprises an external stator housingand an internal rotor within the external stator; where the internalrotor has an axis of rotation, and where the internal rotor is capableof rotating in a first direction around the axis of rotation, and iscapable of rotating in a second direction that is around the axis ofrotation, where the first direction is opposite of the second direction;where each external stator housing comprises progressive recesses andeach internal rotor comprises progressive recesses; where rotation ofthe internal rotor relative to the external stator housing movescomponent inside the pump through the progressive recesses and towardthe delivery duct corresponding to the batching and delivering devicewhen the internal rotor rotates in the first direction, or away from thedelivery duct of the corresponding batching and delivering device whenthe internal rotor rotates in the second direction; b) introducingcomponent into one or more than one modular batching member of themodular dye meter, where the compound to be prepared comprises the oneor more than one component; c) activating the internal rotor of one ormore than one of the batching and delivering devices, thereby causingthe internal rotors to rotate in the first direction, where rotation ofthe internal rotor moves component through the progressive recesses ofthe batching and delivering device through the corresponding deliveryduct and through the dispenser, and thereby into a vessel for containingthe compound; d) causing the rotation of the internal rotor in the firstdirection to cease; e) causing the internal rotor to rotate in a seconddirection, where the second direction is opposite to the firstdirection, thereby moving component back through the delivery duct intothe corresponding batching and delivering device; and f) causing therotation of the internal rotor in the second direction to cease.
 2. Themethod of claim 1, where the first direction is clockwise around theaxis of the internal rotor.
 3. The method of claim 1, where the firstdirection is counter-clockwise around the axis of the internal rotor. 4.The method of claim 1, where the second direction is clockwise aroundthe axis of the internal rotor.
 5. The method of claim 1, where thesecond direction is counter-clockwise around the axis of the internalrotor.